Citylink Tulla Widening – Bulla Road to Power Street

CityLink Tulla Widening – Bulla Road to Power Street

Dr. Kabir Patoary | Principal Engineer – Bridges | GHD Introduction | Presentation outline • Project Background • New bridges: – Bulla Road southbound entry ramp over the Collector Distributor – Pascoe Vale Road over Western Link – Mt Alexander Road over Moonee Ponds Creek

• Widening or modification of existing bridges: – Bulla Road Bridge North Abutment Modification (Separate Paper) – Western Link over Pascoe Vale Road – Moonee Ponds Creek Bridges 1,2,4 and 6 (Separate Paper) – Citylink southbound ramp to power street and Burnley tunnel (Ramp Z) – West Gate Freeway eastbound elevated structure • Conclusions

Presentation Title Introduction | Project Background Airport

• 2 packages of work – Melbourne Airport to Bulla Road • Funded by Federal and State Government • Delivered by VicRoads • Approx. length of 8 kM Bulla Rd to Power St (CTW Section)

– Bulla Road to Power Street (CTW - this project) Bell Pascoe Street • Funded and delivered by Transurban Vale Road • Approx. length of 16 kM New Bell Street • One extra lane in each direction Bridge • Contract Awarded May 2015 • Expected Completion by end 2017 • Total capital cost ~$1.28 billion for both packages

Burnley/Domain Tunnels Presentation Title Introduction | Project Background

• Client Transurban • Contractor CPB – Design &Construct Partner • Main Consultants Aurecon-GHD Joint Venture (AGJV) • Other Consultants Doulgas Partners (geotechnical) SLR (Noise Modelling) KBR (Proof Engineering) PowerPlant (Lighting Design) Hassel (Urban and Architectural) Visionstream (ITS) Davis Langdon & AECOM (IR)

Presentation Title Introduction | Project Background

Total 36 Design Packages, over 4000 Structural Drawings • 3 New Bridges (total 400 m length) • 10 Existing Bridge Widening (total 1800 m length) • 7 Gantry Packages (70 New, 30 Existing) • 3 Noise Wall Packages (40 Noise Walls) • 5 Retaining Wall Packages (10 Retaining Walls) • 7 Pier protection Packages (17 Pier Protection) • 1 Existing Bridge Strengthening package Presentation Title Introduction | Project Background

Major Design Challenges

➢ Large Number of Design Packages

➢ True Brown Field Site

➢ Coordination/Integration between three design offices and four verification offices

➢ Semi-Alliance Environment for D&C

➢ Very tight delivery timeline & Penalty

➢ Stakeholders & IR Approval

Presentation Title New Bridges | Bulla Road southbound entry ramp

Presentation Title New Bridges | Bulla Road southbound entry ramp Major Design Constraints

➢ Existing ground profile require one abutment to be top down with Soil

Nail and another bottom up construction with RE Wall

➢ High bridge skew requiring an in-situ diaphragm at abutment

➢ Construction staging including limited access for crane positioning.

➢ Heavy beams due to high skew and long span resulting in onerous

crane requirements.

Presentation Title New Bridges | Bulla Road southbound entry ramp

Presentation Title New Bridges | Bulla Road southbound entry ramp Design Details-Girder End

Presentation Title New Bridges | Bulla Road southbound entry ramp Design Details-Approach Slab

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link

• Also Called Bell Street Interchange • Existing Bridge → 1 lane for Tullamarine Fwy on Ramp and 1 for Pascoe Vale Rd bound traffic • New bridge → Connecting Bell St to Pascoe Vale Rd traffic – Free up an additional lane on existing bridge – Eliminate dangerous left hand merging

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link

• Complex site requiring the bridge to span over: – Entire CityLink carriageway (11 lanes) – Existing Pascoe Vale Rd exit ramp bridge – Moonee Ponds Creek channel – Craigieburn Railway line ( 2 tracks) – Close proximity to Strathmore Secondary College

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link

• 269m long structure with maximum span of 62m – Spans 1 to 4 → Continuous steel box girders – Spans 5 to 6 → Simply supported Super-T girders – Piers skewed up to 29 degrees to suit site geometry – Curve radius of up to 165m

SPAN 1 SPAN 2 SPAN 3 SPAN 4 SPAN 5 SPAN 6 Abut. B (45m) (62m) (61.5m) (45m) (23.9m) (32m) EJ EJ EJ Abut. A

Span Arrangement

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link Superstructure

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link Substructure

Abutment A Steel Box Pier

Abutment B Transition Pier

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link Analysis and Design

• 3D “spine” grillage deck model using Spacegass • Steel box modelled as single beam elements • Rigid outriggers pinned to webs • Response spectrum analysis for earthquake design due to complex geometry

3D Spacegass Grillage Model

Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link Analysis and Design

• Local steel Finite Element Models in MIDAS Civil • Skew diaphragms beyond “hand calculation” in AS5100.6

Local MIDAS Civil FE Plate Model for Diaphragms Presentation Title New Bridges | Pascoe vale Rd Bridge over Western Link

Construction Challenges

• Complex site required close co-ordination between design and construction teams: – Construction sequence – Crane positioning in constrained site critical • Steel splice locations • Maximum lifting weights – Temporary towers – All major girder lifts to be completed under night road and rail closures

Credit: VicRoads

Presentation Title New Bridges | Mt Alexander Road over Moonee Ponds Creek

Major Constraints

NEW BRIDGE LOCATION • Close proximity to the existing bridge • Requires partial removal of the existing north east approach embankment • New bridge piers/columns are to line up with existing • Soffit level to be no lower than existing • Pedestrian Path under below 1 in 10 ARI

Presentation Title New Bridges | Mt Alexander Road over Moonee Ponds Creek

Presentation Title Existing Bridges Widening| Western Link Bridge over Pascoe Vale Road

•Live running traffic on CityLink north and southbound lanes •The existing noise wall is also to be retained during construction •Depth of structure to achieve existing clearance to Pascoe Vale Rd. •Pier strengthening works require •Existing underground utilities in close proximity to or running below new substructure •Driven piles will require pre boring to minimise vibration effects on gas main

Presentation Title Existing Bridges Widening| Western Link Bridge over Pascoe Vale Road

• Deck Cast in 2 stage • Partial Road Closure • Limit of Deflection and Vibration during deck casting • High strength Low shrink low slump concrete for stitch Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Ramp Z

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

• Existing ramp constructed in 2009/2010 • 420 m of elevated structure in 14 spans • Existing Pier 9 Crosshead spans over West Gate Freeway

Pier1B Span 1 N

Span 2

Abutment Pier 9 Pier 10

Image: Google Earth

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

• Existing Span 1 and 2 are 42m long 2.3m deep composite steel I-Girders, connected to existing CityLink segmental concrete box girders • Existing Span 3 to 14 Super-T beams are 26-32m long

Pier1B Span 1 N

Span 2

Abutment Pier 9 Pier 10

Image: Google Earth

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Design Challenges - Span 1 Widening

• Risk of additional load transferred to Ramp L due to Span 1 widening • No reserved capacity for Ramp L • Avoid deck strengthening due to location of first pier

Existing Deck

Existing Welded Connection

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Design Solution - Span 1 Widening

• Pier location selected to maintain an optimized stiffness of girder • Flexible enough to allow deflection of deck at start of widening and hence no need for deck strengthening • Stiff enough to eliminate additional load transfer to Ramp L • Girder extended under the existing deck, made non-composite for 25% of its length • Pier1B located under existing deck at 1/3 span

Span 1 Plan Span 1 Elevation

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Design Challenges - Span 2 Widening

• Two steel I-girders connected to the existing • Kinked in plan to suit the curved geometry • Excessive twist of girders under girder and deck SW • Unbalanced reactions of girders

Span 2 FE Model - Twisted Girders (SAP2000) Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Design Solution - Span 2 Widening

• Both girders are required to be assemble together on site • Torsional restraint provided by pair of cross bracings at the ‘kinked’ points • Supported on a temporary tower at mid-span till composite action achieved • Minimized the amount of permanent twist

Span 2 Plan

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Design Challenges – Pier 9 Crosshead • Existing crosshead is a precast post-tensioned beam • Existing Super-T beams are supported on a concrete corbel • Crosshead was not designed for future widening • Assessment showed that crosshead suspension reinforcement is not adequate for the new beam loads • Anchoring into crosshead was also impossible due to presence of post-tensioning • Extending existing concrete corbel was not a solution

Existing Post- Tensioning Profile Existing concrete corbel

Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Design Solution – Pier 9 Crosshead

• Steel fabricated saddle with 100mm thick top plates • Transfer loads from bearings to top of crosshead • All components checked for fatigue • Simple structural form and ease of installation achieved

Pier 9 Saddle

Side View Presentation Title Existing Bridges Widening| Ramp Z-Southbound Ramp Bolte to Power St.

Pier 10 Crosshead Design Challenges Design Solution • Independent new concrete column • Limited structural depth available • Two fabricated steel I-girders cantilever • Casting crosshead over live traffic over the West Gate Freeway • Possible West Gate Freeway traffic • Crosshead held to the top of the new disruption column by cast-in stress bars • Shallow structural depth achieved • Easy installation

Independent new column Existing Pier 10

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure

• Total length of widening 1010 m • Total 24 span. Span length varies from 31 m to 56 m • Existing structure is constructed in the mid 1980’s • Existing structure is continuous up to 300 m • Segmental Box Girder balanced cantilever construction. • Widening width varies from 0 to 3.5 m

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure Design Constraints

• The widening work is to be constructed adjacent to live traffic • The widening work crosses a number of existing access roads and tram routes • Existing 3.8 m x 3.8 m Melbourne Water storm water drain close to pier. • Low piling headroom under existing Deck • Piling adjacent and close proximity to existing Westgate Elevated Structure substructures

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure Design Solutions - Superstructure

• For Widening up to 0.8 m

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure Design Solutions - Superstructure

• For Widening up from 0.8 m to 2.4 m

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure Design Solutions - Superstructure

• For Widening up from 2.4 m to 3.2 m

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure Design Solutions - Superstructure

• Transition from I Girder to Box Girder

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure Design Solutions - Substructure

Presentation Title Existing Bridges Widening| Westgate Freeway Eastbound Elevated Structure

Design Solutions - Articulation

Presentation Title Conclusions

• An excellent example of fitting new works within a busy existing road corridor

• Design decisions were heavily influenced by the need to accommodate the existing traffic and associated highway works, and to suit construction staging under operating live traffic

• Major bridgeworks successfully completed and Road open for traffic months ahead

• Close co-ordination with design and construction teams was critical for successful completion

Presentation Title Acknowledgments and Questions

• Acknowledgments − CPB Contractors − Transurban − VicRoads − Douglas Partners − Hassell • Thank you for listening

Presentation Title www.ghd.com citylinktullawidening.vic.gov.au

Presentation Title